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I don't know if this will help, but there is a free program called 'tube miter' online, look it up, download it.... it will print templates for miter joints on all sizes of tube up to around 3.5". It will calculate all angles, and print temps for connecting different sized tubes together of different wall thickness.
Here is a link for pipe joints, enter the numbers and thickness and just hit submit. It opens a printable page with the template on it. I have never used it myself, just came across it and thought it was worth saving.
Miller 211 A.S. and Spoolmate 100
Stickmate LX 235 AC / 160 DC.
Clarke 180 EN Just in case
Spectrum 375 X-Treme.
O/A Medium Radnor Torch, Large Victor Torch.
Milwaukee 14" Chop Saw.
4 x 6 Horizontal Band Saw.
Rockworth 80 Gallon 2 Stage 16 SCFM @ 175 PSI , 15 SCFM @ 90 PSI.
Jackson Passive shade #5 for the plasma.
I almost forgot the Hobart XVP AD Hood.
Hypertherm PowerMax 1000
20" x 40" CNC Mills (2)
16" x 60" engine lathe
65 Ton edwards iron worker
3/16' x 24" power slip roll
16' power feed mitering bandsaw
and other fun toys
those programs are worthless unless you are notching with a saw or a grinder. if you already know the intersection angle, you know the notch angle too. i just fit up a cage yesterday and eyeballed every notch in the car. every tube fit perfect on the first cut.
LINCOLN IDEALARC 250 TIG
LINCOLN SP100 MIG
15 TON X 4' VERSON PRESS
VINTAGE W.F AND JOHN BARNES 15" DRILL PRESS
WILTON C-2 BENCH VISE
HF 20 TON SHOP PRESS
TONS OF OTHER TOOLS
Hope you didn't sprain your shoulder too badly, PATTING YOURSELF ON THE BACK.
That really helped the OP I'm sure.
Syncrowave 250 DX Tigrunner
Dynasty 200 DX
Miller XMT 304 w/714D Feeder & Optima Control
Miller MM 251 w/Q300 & 30A SG
Dialarc 250 AC/DC
Hypertherm PM 600 & 1250
Wilton 7"x12" bandsaw
PC Dry Cut Saw, Dewalt Chop Saw
Milwaukee 8" Metal Cut Saw, Milwaukee Portaband.
Thermco and Smith (2) Gas Mixers
More grinders than hands
I made a set of "jigs" one end has the tubing size I'm fabing about 8" long with the pipe master on it, then I have a second pieace of tubing " I have various lenth's" smaller so it will slide in side the first piece then U can put it in the gap, slide it apart, get your fit with the "pipe master" take it out trasfer it on to you work pieace then do the other end. it works for me. Not perfect and takes a little time but I find its easier than the programs, for the amount of tubing U will waste trying different bends,notches IMO its faster to try it, and it does not fit save it for another project and build another pieace than it is to mess around with a computer.
One thing I've found hard to find out and am still looking for info on is finding what point to go off of from a bend in tubing, since there is no edge, where do you measure from?
Ron Covell has an excellent video on working with tubing - goes into how to accurately use a tube bender. One thing he doesn't mention though if you change material, or even supplier, the spring back on tubing might change. Do a practice bend with each lot and keep notes.
I believe you can actually rent Covell's videos on some web sites.
Con Fuse! Miller Dynasty 350
-Spoolmatic 30A Hypertherm PowerMax 1000G3 Miller Multimatic 200 - awesome portable MIG (and stick and TIG) Miller Maxstar 200DX - portable TIG and stick